Nissan Pick-ups and Pathfinder 1989-1995

Clutch Master Cylinder

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REMOVAL & INSTALLATION



See Figure 1

Replace the clutch master cylinder and slave cylinder as a set for added reliability.

  1. Disconnect the master cylinder pushrod from the clutch pedal.
  2.  



Click image to see an enlarged view

Fig. Fig. 1: Clutch hydraulic system

  1. Remove the hydraulic line from the master cylinder being careful not to damage the compression fitting.
  2.  
  3. Remove the two bolts holding the clutch master cylinder to the engine compartment.
  4.  


WARNING
Brake fluid dissolves paint. Do not allow it to drip onto the body when removing the master cylinder. If any does get on the paint, wipe it off immediately.

To install:
  1. Install the master cylinder and tighten the mounting bolts to 6-8 ft. lbs. (8-11 Nm). Partially tighten the hydraulic line and then tighten the cylinder mounting bolts.
  2.  
  3. Connect the pushrod to the clutch pedal.
  4.  
  5. Bleed the system and adjust the clutch pedal.
  6.  

OVERHAUL



See Figure 2

  1. Disassemble the master cylinder by unscrewing the clutch pedal clevis from the pushrod. Also remove the locknut.
  2.  
  3. Pull off the rubber boot to expose an internal snapring. Remove the snapring and withdraw the piston and compression spring.
  4.  



Click image to see an enlarged view

Fig. Fig. 2: Exploded view of the clutch master cylinder assembly

  1. Take a clean rag and wipe out the inside of the cylinder. Inspect the inside of the cylinder for scoring and deposits. Use crocus cloth or a small hone to refinish the inside of the cylinder. If light honing will not remove score marks replace the cylinder.
  2.  


WARNING
Be careful not to remove too much from the cylinder walls as the cups will not be able to seal the cylinder if the diameter is enlarged excessively.

  1. Wash all metal parts in solvent.
  2.  
  3. Further disassembly should be avoided unless the reservoir is leaking. If the reservoir needs to be replaced, remove the cap and remove the master cylinder reservoir bolt located at the bottom of the reservoir. Tighten the bolt upon reassembly.
  4.  
  5. With new parts from the rebuilding kit assemble the master cylinder. Coat the cylinder wall with clean brake fluid so that the edges of the new cups will not be damaged. Coat the piston with lithium soap based glycol grease.
  6.  

 
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